Microfibrillated Cellulose Polymer Substrate Barrier

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Solution Overview

Problem

Current fiber-based packaging products require thick and costly polymer layers or aluminum to achieve barrier properties, which increase carbon dioxide emissions and hinder recyclability.

Innovation Solution

A paper or paperboard substrate comprising a first fiber-based layer, a second layer of microfibrillated cellulose, and a third layer of polymer, with an optional fourth layer added via atomic layer deposition, providing excellent barrier properties against liquids, vapor, and gases while reducing material thickness and carbon footprint.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thick polymer layers are used to achieve barrier properties, then barrier performance is improved, but production cost increases

Engineering Contradiction:
Improvebarrier performanceVSAvoidproduction cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies composite materials by combining a polymer layer with a microfibrillated cellulose (MFC) layer to create a multi-layer structure. The MFC layer provides barrier properties against oxygen, aromas, and fats, while the polymer layer provides liquid and vapor barrier properties. This composite structure achieves superior overall barrier performance while using thinner total material depth, reducing production costs compared to using thick polymer layers alone.

Inventive Principle:
Principle #40Composite materials

2Reliability

If aluminum layers are used to improve oxygen and light barrier, then barrier properties are improved, but carbon dioxide load increases and recyclability decreases

Engineering Contradiction:
Improveoxygen barrierVSAvoidcarbon dioxide load
Core Design Contradiction:
ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the material parameter from aluminum to microfibrillated cellulose (MFC) while maintaining the barrier function. The MFC layer provides oxygen barrier properties through its dense, crystalline structure and high aspect ratio microfibrils that create tortuous paths for gas permeation. This substitution eliminates the harmful environmental effects of aluminum while achieving comparable or superior oxygen barrier performance.

Inventive Principle:
Principle #35Parameter changes

3Reliability

If thick polymer layers are used to achieve barrier properties, then barrier performance is improved, but material thickness increases

Engineering Contradiction:
Improvebarrier performanceVSAvoidmaterial thickness
Core Design Contradiction:
ReliabilityVSLength of stationary object

Solution Approach 1:

The patent uses composite materials with the MFC layer providing barrier properties in a thin format. The microfibrils in the MFC layer create a tortuous path that effectively blocks gas and vapor permeation without requiring significant thickness. When combined with a thin polymer layer, the composite structure achieves excellent barrier performance with minimal total thickness, avoiding the need for thick polymer layers.

Inventive Principle:
Principle #40Composite materials

4Reliability

If aluminum is used to improve barrier properties, then oxygen barrier is improved, but recyclability decreases

Engineering Contradiction:
Improveoxygen barrierVSAvoidrecyclability
Core Design Contradiction:
ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes the material parameter from aluminum to microfibrillated cellulose (MFC), which is a renewable, biodegradable material derived from wood pulp. The MFC layer provides oxygen barrier properties through its unique microstructure of highly oriented, crystalline microfibrils. This material substitution maintains barrier performance while dramatically improving recyclability and environmental compatibility, as MFC is compatible with paper and cardboard recycling streams.

Inventive Principle:
Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The combination of microfibrillated cellulose and polymer layers enhances adhesion, reduces polymer thickness, and improves barrier properties, achieving superior oxygen, liquid, and vapor resistance with lower carbon emissions and recyclability.

Implementation Method 1

a second layer comprising microfibrillated cellulose

Methodology Applied
Scientific EffectPhysical barrier:

Implementation Method 2

a third layer comprising a polymer

Methodology Applied
Scientific EffectPhysical barrier:

Implementation Method 3

a fourth layer which is added by the aid of atomic layer deposition (ALD)

Methodology Applied
Scientific EffectAtomic layer deposition:

Data Source

PatentEP2516156B1A paper or paperboard substrate, a process for production of the substrate and a package formed of the substrate
Publication Date: 2019.03.20 STORA ENSO OYJ

AI summary

The present invention relates to a paper or paperboard substrate having barrier properties which substrate comprises a first fiber based layer, a second layer comprising microfibrillated cellulose and a third layer comprising a polymer. The invention further relates to a process for the production of said substrate and a package formed of said substrate.